Wheel measurement systems and methods

ABSTRACT

An improved maintenance, inspection, and/or measurement solution is provided. An embodiment of the invention includes a handheld measurement device for measuring an object, such as a railway wheel on a train. The handheld measurement device can comprise a single unit to provide one handed operation and can include various features, such as onboard evaluation, a graphical user interface, and/or a self-health monitor. Additionally, aspects of the invention provide an inspection environment that incorporates preliminary measurement data, wireless communications, and/or historical data into the measurement and evaluation process.

REFERENCE TO RELATED APPLICATIONS

The current application claims the benefit of co-pending U.S.Provisional Application No. 60/723,441, filed on 5 Oct. 2005, which ishereby incorporated herein by reference. The application also is relatedin certain aspects to the co-owned, co-pending U.S. utility patentapplication Ser. No. 11/134,944, filed on 23 May 2005, and entitled“Portable Electronic Measurement” and the co-owned, co-pending U.S.utility patent application Ser. No. 11/136,207, filed on 24 May 2005,and entitled “Inspection Method, System, and Program Product”, both ofwhich are hereby incorporated herein by reference.

FIELD OF THE INVENTION

Aspects of the invention relate generally to wheel measurement, and moreparticularly, to an improved solution for measuring a railway wheel.

BACKGROUND OF THE INVENTION

Railroad cars and engines utilize railway wheels having a standardizeddesign. In general, each railway wheel is made of solid steel and isformed to a very precise pattern. Over time, due to the immense stressplaced on a railway wheel (e.g., an individual car may weigh over300,000 pounds), the railway wheel wears. This wear can lead to anunsafe operating condition, particularly in light of the use of solidaxles on railroad cars/engines, which cannot readily accommodate unevenwear. Eventually, a railway wheel will become unsafe to operate byposing a high potential for derailment or breakage.

FIGS. 1A-B show a portion of an illustrative railway wheel 2 before andafter experiencing wear, respectively. During operation, a tread surface4 supports railway wheel 2 (and the corresponding rail car/engine) as itmoves along the rail, while a flange 6 prevents railway wheel 2 fromleaving the rail due to outward forces exerted on railway wheel 2. Aswear progresses on railway wheel 2, a thickness of flange 6, T′,decreases from an original thickness T. Similarly, due to wear on treadsurface 4, an effective height of flange 6, H′, increases from anoriginal height H.

After sufficient wear, a railway wheel 2 can be recut/retrued so that itcan be safely used. In particular, tread surface 4 and flange 6 areground to form a safe profile of railway wheel 2, such as that shown inFIG. 1A. This operation is expensive and time consuming. As a result, itis desirable to minimize the instances in which a railway wheel 2 isrecut/retrued unnecessarily. To this extent, a railway wheel 2 must havea minimum rim thickness, R, in order to safely operate. The rimthickness of railway wheel 2 can be measured using a reference groove 8,if available, resulting in a rim thickness measurement R_(G), or using arim break point 9, which results in a rim thickness measurement R_(B).

Frequently, railway wheels 2, even when installed on the same railcar/engine, do not experience an even or predictable amount of wear. Tothis extent, railway wheels 2 on the same axle of a rail car/engine maybecome unsafe when the relative diameters are sufficiently different dueto uneven wear. In particular, since railway wheels 2 are connected by asolid axle, a smaller diameter railway wheel 2 may introduce a force inthe system that turns toward the smaller railway wheel 2. As a result ofthe force, the railway wheel 2 may “ride up” over the rail, causing aderailment. As a result, a diameter of railway wheel 2 can be measured,which can be determined based on the measured rim thickness R of thewheel and the corresponding type of railway wheel 2.

As a result, a need exists for accurately measuring various features ofa railway wheel 2, such as flange thickness T, flange height H, rimthickness R, diameter, and/or the like. Errors in measurements can leadto an unacceptable railway wheel 2 remaining in service, which presentsa potential safety and liability hazard, increases noise, wear, and fuelconsumption for the train, and the like. Additionally, a railway wheel 2may be mistakenly condemned when it could have been retrued, whichwastes a viable railway wheel 2. Further, a railway wheel 2 that shouldbe condemned may be sent for retruing, which wastes time and disruptsthe operation of a truing shop.

Several devices have been proposed to obtain measurements of railwaywheel 2. One such device comprises a mechanical caliper-style gauge thatlooks like an inverted “J”. In use, the gauge is hooked onto a railwaywheel 2 and the measurements are read from scale markings imprinted onthe gauge. However, this gauge is difficult to use when railway wheel 2is installed on a rail car/engine due to the presence of othercomponents (e.g., brakes, shock absorbers, axle supports, etc.), as wellas other ambient conditions, such as lighting, precipitation, etc.Additionally, the measurements must be manually recorded, which mayresult in data-entry errors.

To address this situation, several proposals have been made forperforming electronic railway wheel/rail measurement. However, each ofthese proposals includes one or more limitations. For example, someproposals only measure a subset of the required attributes, such as arim profile. Additionally, some proposals are not portable, requireadditional computing capability, and/or cannot provide data to a remotesystem. Further, current solutions are limited in the speed with whichmeasurements can be taken, as well as an overall integration into acomplete wheel management system.

In view of the foregoing, a need exists to overcome one or more of thedeficiencies in the related art.

BRIEF SUMMARY OF THE INVENTION

Aspects of the invention provide an improved maintenance, inspection,and/or measurement solution. An embodiment of the invention includes ahandheld measurement device for measuring an object, such as a railwaywheel on a train. The handheld measurement device can comprise a singleunit to provide one handed operation and can include various features,such as onboard evaluation, a graphical user interface, and/or aself-health monitor. Additionally, aspects of the invention provide aninspection environment that incorporates preliminary measurement data,wireless communications, and/or historical data into the measurement andevaluation process. In this manner, embodiments of the invention canimprove the efficiency and reliability of an inspection and/ormaintenance process for a vehicle having wheels, e.g., a train.

A first aspect of the invention provides a handheld measurement devicecomprising: a system for obtaining a plurality of measurements for awheel; and a system for evaluating at least one of the plurality ofmeasurements with at least one anticipated wheel property to determine avalidity of the at least one of the plurality of measurements.

A second aspect of the invention provides a measurement systemcomprising: a handheld measurement device including: a system formanaging an inspection schedule; a system for obtaining a plurality ofmeasurements for a wheel; and a system for managing a plurality ofmeasurement modes.

A third aspect of the invention provides a handheld measurement devicecomprising: a system for obtaining a plurality of measurements for anobject; and a system for monitoring an operability of the device basedon a set of operational environment attributes of the measurementdevice.

A fourth aspect of the invention provides a method of generating asystem for measuring a set of objects, the method comprising: providinga computer system operable to measure each of the set of objects asdescribed herein.

A fifth aspect of the invention provides a business method for managingwheel measurement and/or a train inspection, the business methodcomprising managing a computer system that performs the processdescribed herein; and receiving payment based on the managing.

The illustrative aspects of the present invention are designed to solveone or more of the problems herein described and/or one or more otherproblems not discussed.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

These and other features of the invention will be more readilyunderstood from the following detailed description of the variousaspects of the invention taken in conjunction with the accompanyingdrawings that depict various embodiments of the invention.

FIGS. 1A-B show a portion of an illustrative railway wheel before andafter experiencing wear, respectively.

FIG. 2 shows a profile and exterior view of another illustrative railwaywheel.

FIG. 3 shows an illustrative environment for managing a set of wheelsaccording to an embodiment of the invention.

FIGS. 4A-C show several illustrative measurement devices according toembodiments of the invention.

FIGS. 5A-B show an illustrative measurement device placed to measure agauge side and a field side of a railway wheel, respectively, accordingto an embodiment of the invention.

FIGS. 6A-C show various views of an illustrative prior art absoluteposition rotational sensor.

FIGS. 7A-C show various views of an illustrative incremental positionrotational sensor according to an embodiment of the invention.

FIGS. 8A-B show two views of an illustrative incremental position linearsensor according to an embodiment of the invention.

FIGS. 9A-B show two views of an alternative incremental position linearsensor according to an embodiment of the invention.

FIGS. 10A-B show two views of an illustrative rim thickness sensor thatfunctions based on the Hall Effect according to an embodiment of theinvention.

FIG. 11 shows a rim thickness sensor placed in two illustrativemeasurement locations on a railway wheel and the resulting measurementgraphs according to an embodiment of the invention.

FIG. 12 shows an illustrative measurement device according to anembodiment of the invention.

FIG. 13 shows a more detailed view of an illustrative group of interfacedevices for a measurement device according to an embodiment of theinvention.

FIG. 14 shows an illustrative process for managing a train inspectionaccording to an embodiment of the invention.

FIG. 15 shows an illustrative process for inspecting a set of wheelsaccording to an embodiment of the invention.

It is noted that the drawings are not to scale. The drawings areintended to depict only typical aspects of the invention, and thereforeshould not be considered as limiting the scope of the invention. In thedrawings, like numbering represents like elements between the drawings.

DETAILED DESCRIPTION OF THE INVENTION

As indicated above, aspects of the invention provide an improvedmaintenance, inspection, and/or measurement solution. An embodiment ofthe invention includes a handheld measurement device for measuring anobject, such as a railway wheel on a train. The handheld measurementdevice can comprise a single unit to provide one handed operation andcan include various features, such as onboard evaluation, a graphicaluser interface, and/or a self-health monitor. Additionally, aspects ofthe invention provide an inspection environment that incorporatespreliminary measurement data, wireless communications, and/or historicaldata into the measurement and evaluation process. In this manner,embodiments of the invention can improve the efficiency and reliabilityof an inspection and/or maintenance process for a vehicle having wheels,e.g., a train. As used herein, unless otherwise expressly noted, theterm “set” means one or more (i.e., at least one) and the phrase “anysolution” means any now known or later developed solution.

For convenience, the remainder of the Detailed Description of theInvention includes the following headers.

I. ILLUSTRATIVE RAILWAY WHEEL MEASUREMENTS

II. WHEEL MANAGEMENT SYSTEM

III. HANDHELD MEASUREMENT DEVICE

-   -   A. DEVICE CONFIGURATIONS    -   B. PLACEMENT FEATURES    -   C. ACQUISITION FEATURES        -   1. ILLUSTRATIVE MEASUREMENT COMPONENTS        -   2. MEASUREMENT EVALUATION AND MODAL OPERATION    -   D. INTERFACE FEATURES    -   E. SELF-HEALTH FEATURES

IV. ALTERNATIVES

I. Illustrative Railway Wheel Measurements

Turning to the drawings, as discussed previously, FIGS. 1A-B show aportion of an illustrative railway wheel 2 before and after experiencingwear, respectively. In general, it is desirable to accurately measurerailway wheel 2 to determine an amount of wear experienced on railwaywheel 2. Based on these measurements, railway wheel 2 can be deemedsafe, sent for recutting/retruing, condemned, or the like. Typically,measurements such as flange thickness T, flange height H, and rimthickness R (e.g., R_(G) based on reference groove 8, R_(B) based on rimbreak 9, and/or the like) are obtained and used to make a determinationwith respect to an operability of railway wheel 2. Additionalmeasurements, such as a flange angle, also can be obtained and used. Itis understood that these measurements and railway wheel 2 are onlyillustrative of various objects and/or measurements, which can bemeasured using an embodiment of the invention. To this extent, theinvention is not limited to railway wheel 2, wheels in general, and/orthese particular measurements.

In any event, FIG. 2 shows a profile and exterior view of anotherillustrative railway wheel 2. As shown, another measurement for railwaywheel 2 is its diameter, D, which is defined as a distance from a pointin the running center of tread surface 4 (FIG. 1A), through a center ofrailway wheel 2, to an equivalent point in the running center of treadsurface 4 on the opposite side of railway wheel 2. Since wear isgenerally even for railway wheel 2, the diameter D can be calculatedusing other available measurement(s). For example, diameter D can becalculated by adding twice the measured rim thickness, e.g., R_(G), to aknown diameter of the reference groove, G. Diameter D can be used inevaluating whether railway wheel 2 can be retrued or must be condemned,whether two railway wheels 2 on the same axle have diameters that differtoo greatly, and/or the like.

In general, railway wheels 2 will comprise a fairly uniform diameter Dregardless of the location on railway wheel 2 at which the measurementsare obtained, e.g., D′ will be substantially similar to D. However,railway wheels 2 may experience uneven wear in some circumstances. Forexample, railway wheel 2 may have slid significantly on a rail due to abrake malfunction or the like. In this case, tread surface 4 (FIG. 1A)is preferentially worn at a point of contact with the rail during thesliding, yielding a flat spot F. Flat spot F will result in a diameterD″ that is less than diameter D. The presence of flat spot F candrastically increase wear, increase noise pollution, reduce efficiency,create more dangerous conditions, and/or the like. Consequently, anothermeasurement that can be obtained for railway wheel 2 is an extent and/ordepth of flat spot F.

II. Wheel Management System

An embodiment of the invention provides an improved wheel managementsystem for obtaining wheel measurements and/or taking one or moreactions in response to these measurements. To this extent, FIG. 3 showsan illustrative environment 10 for managing a set of wheels according toan embodiment of the invention. Environment 10 includes a computersystem 12 that can perform the process described herein in order tomanage wheels and/or wheel data 60. In particular, computer system 12 isshown including a computing device 14 that comprises a wheel managementprogram 30, which makes computing device 14 operable to process wheeldata 60 according an embodiment of the invention. Further, computersystem 12 is shown including a measurement device 40 and a preliminarymeasurement system 50 for obtaining wheel data 60 for a set of wheels(e.g., on a train). Computer system 12 also can include a dynamicsupport system 52 for updating the operating capacity of measurementdevice 40. Operation of the various systems/devices of computer system12 are discussed further herein. However, it is understood thatalternative embodiments of computer system 12 may not include all of thesystems/devices shown and described and/or may include additionalsystems/devices not shown.

Regardless, computing device 14 is shown including a processor 20, amemory 22A, an input/output (I/O) interface 24, and a bus 26. Further,computing device 14 is shown in communication with an external I/Odevice/resource 28 and a storage device 22B. In general, processor 20executes program code, such as wheel management program 30, which isstored in a storage system, such as memory 22A and/or storage device22B. While executing program code, processor 20 can read and/or writedata, such as wheel data 60, to/from memory 22A, storage device 22B,and/or I/O interface 24. Bus 26 provides a communications link betweeneach of the components in computing device 14. I/O device 28 cancomprise any device that transfers information between a user (anindividual and/or another device/system) and computing device 14. Tothis extent, I/O device 28 can comprise a user I/O device to enable anindividual user to interact with computing device 14 and/or acommunications device to enable a system user, such as measurementdevice 40 and/or preliminary measurement system 50, to communicate withcomputing device 14 using any type of communications link.

In any event, computing device 14 can comprise any general purposecomputing article of manufacture capable of executing program codeinstalled thereon. However, it is understood that computing device 14and wheel management program 30 are only representative of variouspossible equivalent computing devices that may perform the processdescribed herein. To this extent, in other embodiments, thefunctionality provided by computing device 14 and wheel managementprogram 30 can be implemented by one or more computing article(s) ofmanufacture that includes any combination of general and/or specificpurpose hardware and/or program code. In each embodiment, the programcode and hardware can be created using standard programming andengineering techniques, respectively.

It is understood that measurement device 40, preliminary measurementsystem 50, and/or dynamic support system 52 each can comprise similarcomponents as shown and described with respect to computing device 14.Additionally, the various devices/systems in computer system 12 cancommunicate over any combination of various types of communicationslinks, such as a network, a shared memory, or the like, to perform theprocess described herein. Further, while performing the processdescribed herein, one or more devices/systems in computer system 12 cancommunicate with one or more other devices/systems external to computersystem 12 using any type of communications link. Regardless, thecommunications link(s) can comprise any combination of various types ofwired and/or wireless links; comprise any combination of one or moretypes of networks; and/or utilize any combination of various types oftransmission techniques and protocols.

In an embodiment of the invention, measurement device 40 comprises ahandheld measurement device that communicates with computing device 14and/or dynamic support system 52 using any type of wirelesscommunications link. Further, measurement device 40 can comprise anetwork-addressable computing device, which enables communicationsbetween measurement device 40 and computing device 14, dynamic supportsystem 52, and/or other devices/systems to occur over any public orprivate network, such as a local area network (LAN), the Internet, orthe like. For example, measurement device 40 can include acommunications device that complies with the IEEE 802.11 wirelessEthernet standard (e.g., a Wireless-Fidelity (Wi-Fi) network device) toimplement wireless network communications. It is understood thatmeasurement device 40 can utilize any combination of various wirelesscommunications solutions, including IEEE 802.15.4 (e.g., “ZigBee”)compliant communications, infrared communications, acoustic datatransfer, laser communications, and/or the like. Additionally, it isunderstood that the communications can be secured (e.g., encrypted)using any solution.

As discussed herein, measurement device 40 obtains wheel data 60 for awheel, such as a railway wheel. To this extent, measurement device 40 isshown including an interface module 42, an acquisition module 44, anevaluation module 46, a mode module 48, and a self-health module 49.Additionally, wheel management program 30 enables computer system 12 tomanage the evaluation of a set of wheels and the corresponding wheeldata 60. To this extent, wheel management program 30 is shown includinga scheduling module 32, a history module 34, a data module 36, and anaction module 38. Operation of each of these modules is discussedfurther herein. However, it is understood that some of the variousmodules shown in FIG. 3 can be implemented independently, combined,and/or stored in memory of one or more separate computing devices thatare included in computer system 12. Further, it is understood that someof the modules and/or functionality may not be implemented, oradditional modules and/or functionality may be included as part ofcomputer system 12.

Regardless, the invention provides a solution for managing a set ofwheels. To this extent, environment 10 can be implemented at a trainyard or the like, in which railway wheels included on a train aremeasured and evaluated for continued operation. Similarly, environment10 can be implemented at a wheel manufacturing and/or retruing location.It is understood that environment 10 can be implemented in various otherembodiments and applications and therefore is not limited to theseillustrative applications.

In any event, scheduling module 32 can manage a wheel measurementschedule for a set of railway wheels, such as all railway wheels on atrain, newly manufactured/retrued railway wheels, and/or the like. Tothis extent, FIG. 14 shows an illustrative process for managing a traininspection according to an embodiment of the invention. Referring toFIGS. 3 and 14, in process P1, scheduling module 32 can obtain traindata 64 for a train to be evaluated (e.g., from an individual user,another system, and/or the like). The train data 64 can includeinformation on the train, such as a train identification, a scheduledarrival, a destination, a track number, a scheduled departure time, anumber of vehicles (e.g., locomotive(s), railcar(s), etc.), and/or thelike. Using train data 64, scheduling module 32 can generate aninspection schedule for the train. The inspection schedule can includean identifier for the train, an estimated start time for the inspection,a location of the train, an estimated time period for completing theinspection, as well as a blank inspection record for each vehicle on thetrain, and railway wheel on the vehicle.

When implemented at a rail yard, a plurality of trains may be present inthe rail yard, each requiring inspection. To this extent, schedulingmodule 32 can manage a plurality of inspection schedules, one for eachtrain. In particular, scheduling module 32 can schedule an order of theinspections based on the arrival/departure of each train, a number ofvehicles in each train, and/or the like. Once completed, schedulingmodule 32 can transmit one or more inspection schedules to measurementdevice 40. In an embodiment, a user 16, such as a train inspector,carries measurement device 40 and performs the inspection according tothe inspection schedule. To this extent, computer system 12 can includea plurality of measurement devices 40, one for each of a plurality ofinspectors. In this case, scheduling module 32 can transmit a subset ofthe inspection schedules (e.g., one train each) and/or a subset of aparticular inspection schedule (e.g., first twenty vehicles/last twentyvehicles) to each measurement device 40 for implementation by users 16.

Additionally, train data 64 can be linked (e.g., using an identifier) toone or more vehicles that are part of the train. In this case, inprocess P2, history module 34 can obtain vehicle data 62 for eachvehicle included in the train using the link. The vehicle data 62 caninclude information such as the contents, a weight, an operatinghistory, and/or the like, for the vehicle. Further, train data 64 and/orvehicle data 62 can include information on the relative locations of thevehicles in the train. Still further, the vehicle data 62 can be linked(e.g., using an identifier) to wheel data 60 for each railway wheel onthe vehicle. To this extent, in process P3, history module 34 can obtainwheel data 60 for each railway wheel on the train, which can include anoperating history, a measurement history, etc., for the wheel, for a setof wheels on an axle, and/or the like. It is understood that wheel data60, vehicle data 62, and train data 64 can be stored using any solution.For example, the data can be stored as entries in tables of a relationaldatabase. Additionally, it is understood that scheduling module 32and/or history module 34 can obtain the data using any solution, e.g.,from another system, from a storage device based on an identifier, asinput from a user, and/or the like.

Scheduling module 32 also can include vehicle data 62 and/or wheel data60 in an inspection schedule for a train. For example, scheduling module32 can pre-populate an inspection record for each vehicle on the trainwith an identification of the vehicle (e.g., obtained from vehicle data62), an identification/location for each wheel on the vehicle (e.g.,obtained from wheel data 60), and/or the like. In this case, during aninspection, an inspector (user 16) can visually confirm that the vehiclebeing inspected matches the vehicle identified in the record, that thewheel being inspected matches the wheel identified in the record, and/orthe like. When a mismatch occurs, the data can be modified, a temporaryrecord can be created, and/or the like, and the vehicle/wheel data canbe later updated and corrected. In this manner, a vehicle/wheelinspection history can be accurately maintained and updated.

Still further, in process P4, data module 36 can obtain preliminarymeasurement data for the railway wheels on the train from preliminarymeasurement system 50 using any solution. Preliminary measurement system50 can comprise any measurement solution that obtains wheel data 60 foreach railway wheel on the train. In an embodiment of the invention,preliminary measurement system 50 is capable of obtaining wheel data 60while the train is moving (e.g., as the train enters the yard). To thisextent, preliminary measurement system 50 can comprise a fixed platformor the like that obtains wheel data 60 using a contactless solution(e.g., line(s) of light), such as those shown and described in U.S. Pat.No. 6,768,551 and commonly owned, co-pending U.S. patent applicationSer. No. 11/324,894, filed on 4 Jan. 2006, and entitled “Optical WheelEvaluation”, both of which are incorporated herein by reference.Similarly, in a manufacturing/truing shop or the like, preliminarymeasurement system 50 can comprise any measurement solution that obtainswheel data 60 for each manufactured/retrued railway wheel, e.g., using acontactless solution.

Subsequently, action module 38 can process the preliminary measurementdata to determine whether any additional inspection actions should beperformed, and scheduling module 32 can generate an inspection schedulebased on the determination. To this extent, in process P5, action module38 can flag any suspect wheel(s) based on the preliminary measurementdata. For example, action module 38 can determine whether thepreliminary measurement data indicates that a railway wheel includes aflat spot, is out-of-round, includes damage, and/or the like. If so,scheduling module 32 can add a follow up evaluation to be performed byuser 16, e.g., using measurement device 40 to the inspection schedule.For example, as described further herein, user 16 can use measurementdevice 40 to measure a severity of a flat spot. Alternatively, user 16can perform a manual/visual inspection of the railway wheel and manuallyenter a result of the follow up inspection into measurement device 40 asmeasurement data.

In process P6, a set of measurement devices 40 and/or wheel managementsystem 30 can measure and evaluate the wheels. During this process, datamodule 36 can obtain measurement data from each measurement device 40using any solution. In one embodiment, data module 36 receives themeasurement data via a wireless communications link. In this case, wheelmanagement program 30 can process the measurement data concurrently withan ongoing inspection. Alternatively, data module 36 can obtain themeasurement data once the inspection has completed, e.g., via a wiredcommunications link. In either case, history module 34 can store themeasurement data as wheel data 60. Further, history module 34 can updatevehicle data 62 and/or train data 64 based on the measurement data,e.g., upon completion of the inspection, history module 34 can updatedata on a last inspection of the vehicle/train.

Regardless, in process P7, action module 38 can process the measurementdata and/or results and schedule/perform any action(s) required toaddress defective railway wheel(s) and/or railway wheelconfiguration(s). For example, action module 38 may determine that oneor more railway wheels require replacement, retruing, reconfiguration,and/or the like. Typically, a railway wheel will require replacement orretruing when it has worn too much, has physical damage, or the like. Arailway wheel may require reconfiguration when a difference between tworailway wheels on the same axle and/or a difference between a railwaywheel with other railway wheels on a vehicle is sufficiently large.Regardless, action module 38 can generate a set of actions (e.g., anaction schedule), which is subsequently implemented by individual(s) atthe rail yard. To this extent, action module 38 can communicate theaction(s) to one or more maintenance individuals, who can start toperform the required action(s) while the remainder of the inspection isbeing completed by user(s) 16. In this manner, a turn around time forinspecting a train can be reduced.

Additionally, computer system 12 includes a dynamic support system 52.Dynamic support system 52 can provide remote programming/maintenance formeasurement device 40 to help ensure its proper operation. To thisextent, dynamic support system 52 can update one or more modules (e.g.,program code, database, and/or the like) in measurement device 40 toimprove accuracy, add functionality (e.g., a new measurement of a wheel,which can be calculated using other measurement data), customizefunctionality (e.g., custom calibration tables for custom wheels),and/or the like. For example, a vendor/manufacturer of measurementdevice 40 may improve a calibration routine included in acquisitionmodule 44, and use dynamic support system 52 to download the update toacquisition module 44 using a wireless network communications link. Itis understood that the update from dynamic support system 52 can beperformed in response to a request initiated by user 16, automaticallyin response to a periodic polling performed by measurement device 40,and/or the like. Further, the update can be limited to times whenmeasurement device 40 is not being used, is being recharged, and/or thelike.

Additionally, dynamic support system 52 can enable user 16 to obtainhelp and/or technical support via a wireless Internet connection or thelike. To this extent, a user guide, tutorials, help information, and/orthe like, can be obtained from dynamic support system 52 and presentedto user 16 by measurement device 40. Further, operational parameters formeasurement device 40 can be altered using dynamic support system 52.For example, an operating language can be modified from a defaultlanguage to an alternative language. Similarly, user 16 can customizevarious presentation aspects (e.g., sounds, images, colors, size, etc.)of a user interface of measurement device 40.

While dynamic support system 52 is shown in communications withmeasurement device 40, it is understood that dynamic support system 52can communicate with computing device 14 and/or preliminary measurementsystem 50. To this extent, dynamic support system 52 also can providesoftware-related updates (e.g., improved calculations, additionalfunctionality, etc.) to preliminary measurement system 50 and/or wheelmanagement program 30. Further, dynamic support system 52 can providetechnical support information on any of the devices/systems to a user ofwheel management program 30. Still further, in another embodiment,rather than communicating directly with measurement device 40 orpreliminary measurement system 50, dynamic support system 52 cancommunicate with wheel management program 30, which in turn can providethe data (e.g., updates, technical support, etc.) to measurement device40 and/or preliminary measurement system 50.

III. Handheld Measurement Device

An embodiment of the invention provides an improved measurement device40 for measuring objects, such as railway wheels. To this extent,measurement device 40 includes an acquisition module 44 that includesvarious components for measuring a railway wheel. In particular,acquisition module 44 measures a railway wheel and automatically storesthe measurement(s) as electronic data. As discussed herein, measurementdevice 40 can include any combination of one or more of variousfeatures, which improve the reliability, accuracy, and/or the like, ofthe measured data, improve the usability of measurement device 40,enhance the functionality of measurement device 40, and/or the like,over current devices used in the measurement of railway wheels.

It is understood that measurement device 40 includes one or morecomputing devices. The computing device(s) implement some or all of thefunctions of the various modules as discussed herein. For example, acomputing device can include one or more programs that implementfunctionality for each of the modules. To this extent, the computingdevice can interface with various sensors, emitters, I/O interfaces,communications devices, and/or the like, which can be included inmeasurement device 40. Further, the computing device can providetemporary and/or long term storage of data used in the operation of thevarious modules. Still further, the various modules can be implementedin measurement device 40 using a modular approach, which enables asubsystem to be removed/examined without harming or causing failure inanother module. In this manner, a module can be quickly replacedenabling measurement device 40 to be returned to service while thereplaced module is separately analyzed.

A. Device Configurations

FIGS. 4A-C show several illustrative measurement devices 40A-C accordingto embodiments of the invention. Measurement devices 40A, 40C includesimilar configurations as shown and described in U.S. Pat. No. 4,904,939and the co-pending, co-owned U.S. patent application Ser. No.11/134,944, filed on 23 May 2005, and entitled “Portable ElectronicMeasurement”, both of which are hereby incorporated herein by reference.However, measurement device 40B comprises a single unit, which providesfor improved ease of operation and endurance for measurement device 40B.For example, the single unit enables user 16 (FIG. 3) to use measurementdevice 40B using a single hand. In this manner, user 16 can use his/herother hand for balance, to hold additional equipment, and/or the like.Further, the lack of a connection to a second unit eliminates potentialbreakage points of measurement device 40B (e.g., broken connection,inlets for water or dirt, etc.). Still further, the various componentsof measurement device 40B can operate in an integrated manner, whichprovides reduced power demands over previous measurement devices.

In an event, measurement device 40A-C can comprise a rugged exteriorcasing that is designed to withstand the rigors of use in a train yard.To this extent, the casing can include attachment points for a holster,lanyards, straps, and/or the like, for carrying measurement device40A-C. Additionally, the casing can include safety grips to assist inthe safe and accurate placement of measurement device 40A-C on a railwaywheel. Further, the casing can include protection for sensors and otherelectronics, such as protective windows and/or coatings for contactand/or near contact sensors. For example, an artificial colorlesssapphire window can be included to cover a display unit, light sensor,light emitter, and/or the like. Use of the sapphire window provides ahard and durable solution for protecting against a substantial amount ofabuse, while permitting the transmission of light. Other alternatives,such as crystallized carbon (diamond) can be incorporated in measurementdevice 40A-C to protect such components.

Preventing measurement device 40A-C from being harmed in various weatherconditions can be important when it is used in a train yard environment.To this extent, the casing can be sealed along multiple points (e.g.,using screws, clamping mechanisms, and/or the like) with a gasket tohelp ensure protection from external elements at all locations of thecasing. However, in order to perform maintenance on measurement device40A-C, the casing may need to be opened and resealed. To this extent,the casing can be sealed using helicoil screw points, which can increasethe durability and simplify repair over the use of standard screws.Helicoil screw points are manufactured by boring an initial hole in asofter substance (e.g., aluminum) and inserting a coiled wire into thehole. The coiled wire provides more durable threads for the screw/boltthat is inserted.

It is understood that numerous alternatives to measurement devices 40A-Care possible under various embodiments of the invention. To this extent,one or more of the features shown for one of measurement devices 40A-Ccan be included in the other of measurement devices 40A-C. In anembodiment of the invention, the measurement device includes a personalcomputing device, such as a personal data assistant (PDA), incommunications with a sensor head as shown and described in theco-owned, co-pending U.S. utility patent application Ser. No.11/136,207, filed on 24 May 2005, and entitled “Inspection Method,System, and Program Product”, which is hereby incorporated herein byreference. In this case, the sensor head, which can be configuredsimilar to measurement device 40B, can communicate with the personalcomputing device using a wireless communications link or the like, andsome or all of the processing of the measurement data obtained by thesensor head can be performed on the personal computing device ratherthan on the sensor head. In any event, further details of the inventionwill be shown and described with reference to measurement device 40B asan illustrative device configuration.

B. Placement Features

Acquisition module 44 (FIG. 3) can include a set of placement sensorsthat can detect when measurement device 40B, and therefore a set ofsensing devices of measurement device 40B, is correctly aligned with arailway wheel for obtaining measurements of the railway wheel. FIGS.5A-B show measurement device 40B placed to measure a gauge side and afield side of railway wheel 2, respectively, according to an embodimentof the invention. As illustrated, measurement device 40B includes a pairof non-adjusting front contact sensors 70A-B, each of which activateswhen in contact with railway wheel 2. Acquisition module 44 candetermine whether measurement device 40B is correctly aligned withrailway wheel 2 for measurement based on the activation status ofsensors 70A-B.

For example, when neither sensor 70A-B is active, acquisition module 44(FIG. 3) can determine that measurement device 40B is not properlylocated for measurement and disable the acquisition of measurement data.Further, acquisition module 44 can determine when one sensor 70A-B isactive and the other is not active. In this case, interface module 42can notify user 16 (FIG. 3), e.g., aurally, visually, or the like, thatmeasurement device 40B is tilted to one side. To this extent,acquisition module 44 can determine which sensor 70A-B is inactive, andinterface module 42 can notify user 16 of the correct action to take(e.g., tilt left/right). Interface module 42 also can notify user 16when sensors 70A-B indicate that measurement device 40B is correctlyaligned with railway wheel 2.

C. Acquisition Features

Regardless, when properly placed, acquisition module 44 (FIG. 3) canmeasure railway wheel 2. For example, user 16 (FIG. 3) can initiate themeasurement using any solution. Alternatively, acquisition module 44 canautomatically measure railway wheel 2 and interface module 42 can informuser 16 when the measurement is complete. The manner in which themeasurement is initiated can be selected by user 16. Further, user 16can select to override the determination of an improper position ofmeasurement device 40B and obtain measurements regardless of the statusof sensors 70A-B (e.g., when one or both of sensors 70A-B are notproperly functioning).

1. Illustrative Measurement Components

Acquisition module 44 (FIG. 3) includes a set of sensors for obtainingmeasurements of an object, such as railway wheel 2. To this extent, whenmeasurement is desired, acquisition module 44 can obtain data from eachof the set of sensors and store the data as wheel data 60 (FIG. 3) forrailway wheel 2. The set of sensors can comprise numerous disparatetypes of sensors, a single type of sensor, or the like. For measuring arailway wheel, the set of sensors can include a flange height sensor 72,a flange thickness sensor 74, and a rim thickness sensor 76.

In an embodiment of the invention, measurement device 40B is placed onrailway wheel 2 in two positions that enable acquisition module 44 (FIG.3) to obtain a complete set of measurements for railway wheel 2. Inparticular, as shown in FIG. 5A, measurement device 40B is placed suchthat rim thickness sensor 76 is on a gauge side of railway wheel 2. Inthis placement, flange height sensor 72 can measure flange height H(FIG. 1A), flange thickness sensor 74 can measure a flange thickness T(FIG. 1A), and rim thickness sensor 76 can measure a rim thickness R_(B)(FIG. 1A). Additionally, as shown in FIG. 5B, measurement device 40B isplaced such that rim thickness sensor 76 is on a field side of railwaywheel 2. In this placement, rim thickness sensor 76 can measure a rimthickness R_(G) (FIG. 1A).

Flange thickness sensor 74 can be implemented using any solution. Forexample, FIGS. 6A-C show various views of an illustrative prior artabsolute position rotational sensor 80. Rotational sensor 80 includes awheel 82 and a finger 84. In operation, finger 84 contacts flange 6(FIG. 1A), causing wheel 82 to turn. Wheel 82 includes a plurality ofpositional tracks, which include openings that generate a unique patternbased on a position of finger 84. For each positional track, rotationalsensor 80 includes a light emitter 86 and corresponding light sensor 88.A position of finger 84, and therefore a thickness of flange 6, can bedetermined by the pattern detected by sensors 88. In an embodiment ofthe invention, the positional tracks on wheel 82 form a magnetic patternand rotational sensor 80 includes only a set of magnetic sensors. Inthis case, the light emitters 86 and light sensors 88 are not required,thereby reducing the operating requirements for rotational sensor 80.

Rotational sensor 80 requires substantial design and precisemanufacturing to ensure that no duplicate sequences are included in thepositional tracks. Further, a large number of positional tracks may berequired to provide a sufficient measurement accuracy. To this extent,an embodiment of the invention uses one or more incremental positionencoders rather than the prior art absolute position encoders. Ingeneral, an incremental position encoder is easier to design andconstruct. An incremental position encoder includes a single positionaltrack having evenly spaced openings/pattern that provides a desiredresolution.

FIGS. 7A-C show various views of an illustrative incremental positionrotational sensor 80A, which can be used as a flange thickness sensor 74(FIG. 5A) according to an embodiment of the invention. Rotational sensor80A includes a single positional track, which includes a regular patternof spacing that permits a resolution of a rotational position ofrotational sensor 80A to any desired level. In operation, rotationalsensor 80A includes a stop sensor 85 that detects when wheel 82/finger84 are in a fully extended state (e.g., finger 84 is not contacting anyobject). When stop sensor 85 is activated, a counter is set to zero.Subsequently, as finger 84 and wheel 82 move due to contact with anobject, such as flange 6 (FIG. 1A), rotational sensor 80A counts anumber of openings that pass between emitter 86 and sensor 88. In orderto maintain an accurate count, rotational sensor 80A can detect adirection of movement of finger 84 and wheel 82. In this manner,rotational sensor 80A can subtract from the number of openings whenfinger 84 is moving toward stop sensor 85, and add to the number ofopenings when finger 84 is moving away from stop sensor 85. It isunderstood that incremental position rotational sensor 80A can beimplemented without an emitter 86, e.g., when sensor 88 comprises amagnetic sensor.

Returning to FIGS. 5A-B, flange thickness sensor 74 can comprise anabsolute position rotational sensor 80 (FIG. 6A) or an incrementalposition rotational sensor 80A (FIG. 7A). Similarly, flange heightsensor 72 can be implemented using an absolute position rotationalsensor 80 or an incremental position rotational sensor 80A.Alternatively, flange height sensor 72 and/or flange thickness sensor 74can comprise an absolute/incremental position linear sensor. Forexample, FIGS. 8A-B show two views of an illustrative incrementalposition linear sensor 90 according to an embodiment of the invention.Linear sensor 90 includes a shaft 92, which is mounted on a plunger 94(e.g., piston, slide, gears, or the like), for moving shaft 92 into/outfrom a housing 91. In this embodiment, shaft 92 includes a positionaltrack, which includes openings that pass through emitter 96 and sensor98. Sensor 98 maintains a count of the number of openings that havepassed based on the sensed light generated by emitter 96 and a directionof movement of shaft 92. Linear sensor 90 also can include a stop sensoras discussed with respect to incremental position rotational sensor 80A(FIG. 7A).

When not in operation, shaft 92 can be normally extended beyond housing91 or contained within housing 91. In the former case, shaft 92 willmove in toward housing 91 upon contact with an object causing sensor 98to increment a counter for each opening that passes thereby.Additionally, a stop sensor can be placed to detect when shaft 92 is inthe fully extended position. In the latter case, to obtain ameasurement, plunger 94 can move shaft 92 out from housing 91 untilshaft 92 contacts an object. In this case, a stop sensor can be placedto detect when shaft 92 is in the fully retracted position. It isunderstood that various alternative configurations of incrementalposition linear sensor 90 are possible. For example, FIGS. 9A-B show twoviews of an alternative incremental position linear sensor 90A accordingto an embodiment of the invention. In this case, shaft 92 includes aflange 93, which comprises a positional track that is sensed by sensor98 as shaft 92 and flange 93 move into/out of housing 91. Additionally,it is understood that either linear sensor 90, 90A could be configuredwith a plurality of position tracks for encoding an absolute position ofshaft 92.

Returning to FIGS. 5A-B, rim thickness sensor 76 can comprise asufficient length to measure a rim thickness R_(G), R_(B) for any typeof railway wheel 2. In particular, rim thickness sensor 76 can extend toa location that is below reference groove 8 (FIG. 1A) and/or rim breakpoint 9 (FIG. 1A) of a railway wheel 2 having the largest rim thicknessR_(G), R_(B). In this manner, acquisition module 44 (FIG. 3) can measureall types of railway wheels 2. Alternatively, rim thickness sensor 76can be configured to measure a subset of possible railway wheels 2,which can enable rim thickness sensor 76 to be smaller, therebyrequiring less operational power and less space.

Rim thickness sensor 76 can measure rim thicknesses R_(G), R_(B) (FIG.1A) using any solution. For example, rim thickness sensor 76 cancomprise an array of sensors that function on the eddy currentprinciple. Alternatively, rim thickness sensor 76 can comprise an arrayof sensors that function based on the Hall Effect. The Hall Effectpermits the detection and measurement of a metallic object based on itseffect on a biasing magnetic field within a relatively wide range ofdistance from the metallic object. To this extent, use of such an arrayof sensors can enable them to be covered with a thicker protectivecovering than possible with eddy current principle-based sensors, whichcan extend the durability and operability of the sensor array. Further,currently available Hall Effect sensors that are relatively inexpensiveand rugged can be incorporated as rim thickness sensor 76.

FIGS. 10A-B show two views of an illustrative rim thickness sensor 76that functions based on the Hall Effect according to an embodiment ofthe invention. Rim thickness sensor 76 includes an array of Hall Effectsensors, such as Hall Effect sensors 100A-B, which are placed in a pairof staggered rows along a top surface of a ferrite core 102. Core 102 iswound with a conductive wire, such as copper, to produce a coil 104.When acquisition module 44 (FIG. 3) supplies an electrical current tocoil 104, a magnetic field 106 is produced, which is vertically orientedwith respect to sensors 100A-B. A current through Hall Effect sensors100A-B will vary based on an amount of metal in close proximity tosensors 100A-B.

FIG. 11 shows a rim thickness sensor 76 placed in two illustrativemeasurement locations on a railway wheel 2 and the resulting measurementgraphs 110A-B generated by rim thickness sensor 76 for each measurementlocation according to an embodiment of the invention. As illustrated,points P₁₋₆ can be readily detected using the two measurement locationsand the resulting measurement graphs 110A-B. Using some or all of pointsP₁₋₆, rim thicknesses R_(G) and R_(B) can be calculated using anysolution.

It is understood that the measurements and the sensors described hereinare only illustrative of various measurements/sensors that can beobtained by/incorporated into acquisition module 44 (FIG. 3). Forexample, acquisition module 44 can use radiation, such as lasertriangulation as shown and described in the co-owned, co-pending U.S.utility patent application Ser. No. 11/134,944, filed on 23 May 2005,and entitled “Portable Electronic Measurement”, which is herebyincorporated herein by reference, to obtain one or more measurements ofrailway wheel 2 (FIG. 5A). Further, acquisition module 44 can use anelectromagnetic acoustic transduction approach, such as that shown anddescribed in U.S. Pat. No. 6,523,411, which is hereby incorporatedherein by reference. In this case, acquisition module 44 can direct asurface wave towards railway wheel 2 (FIG. 5A) and can sense thereflection of the surface wave. To this extent, acquisition module 44can obtain additional measurements. For example, a middle of a wheeltread of a transit wheel may be interrogated (using, for example, shearvertical waves in pulse-echo mode) to return a tread thickness for thetransit wheel. Since transit wheel inner diameters are well defined,this provides both a surface for returning the tread thickness signal,and a known dimension to which the tread thickness may be added in orderto arrive at an accurate diameter estimate.

Additionally, acquisition module 44 (FIG. 3) can include sufficientsensors to obtain all desired measurements of a railway wheel 2 (FIG.5A) in a single placement. To this extent, FIG. 12 shows an illustrativemeasurement device 40D according to an embodiment of the invention.Measurement device 40D includes two rim thickness sensors 76A-B, whichcan obtain measurements for the rim thickness on both the gauge side andfield side of railway wheel 2. Further, measurement device 40D caninclude a flange thickness sensor 74, flange height sensor 72, andcontact sensor(s) 70A, which can operate as shown and described herein.

2. Measurement Evaluation and Modal Operation

FIG. 15 shows an illustrative process for inspecting a set of wheelsaccording to an embodiment of the invention, which can be implemented onmeasurement device 40. Referring to FIGS. 3 and 15, in general, modemodule 48 can manage a plurality of operating modes for measurementdevice 40. For example, mode module 48 can set measurement device 40 toa normal mode of operation, during which the set of wheels are measured.In particular, during a normal measurement mode, mode module 48 canmanage an inspection schedule for a train. The inspection schedule caninclude the number of vehicles to be inspected as well as the wheels foreach vehicle. In this case, mode module 48 can prompt user 16 to placemeasurement device 40 on a particular wheel of a vehicle and obtain themeasurements. When required, measurement device 40 can be placed on thewheel in multiple locations (e.g., field side and gauge side of arailway wheel). Mode module 48 can prompt to obtain measurements for therailway wheels of a vehicle/train in any desired order.

Regardless, as part of the inspection schedule, in process M1,acquisition module 44 obtains a set of measurements for a railway wheeland stores the measurements on measurement device 40. Measurement device40 can include an evaluation module 46 that, in process M2, evaluatessome or all of the set of measurements. For example, evaluation module46 can determine an operability of the wheel. In particular, evaluationmodule 46 can determine whether the wheel remains within safe operatinglimits. If not, evaluation module 46 can calculate the requirements forretruing the wheel (e.g., by subtracting the flange thickness from therim thickness value) to determine if the wheel can be retrued. If it ispossible, evaluation module 46 can calculate a set of more preciseretruing values and flag the wheel for retruing. If it is not possible,evaluation module 46 can flag the wheel for condemnation.

Further, evaluation module 46 can evaluate some or all of the set ofmeasurements with one or more anticipated wheel properties to determinea validity of the evaluated measurement(s). For example, user 16 and/orscheduling module 32 can indicate a type/model of wheel being measured.Evaluation module 46 can use a set of maximum measurements to comparewith the obtained measurements and ensure that the obtained measurementsare within the maximum measurements. Similarly, evaluation module 46 canuse a minimum measurement for one or more measurements and ensure thatthe measurement is above the minimum measurement.

To this extent, evaluation module 46 can obtain a set of previousmeasurements for the railway wheel. For example, history module 34 canobtain wheel data 60 based on a train scheduled to be inspected andprovide the measurement history for one or more railway wheels on thetrain for use by evaluation module 46. After a railway wheel ismeasured, evaluation module 46 can compare the set of measurements tothe set of previous measurements to determine whether any anomalies arepresent in the measurements. For example, the new set of measurementsmay indicate that the railway wheel has “grown” since the previousmeasurement, an impossibility. Further, the measurement may indicatewear that is below/beyond and expected range of wear.

There are several potential sources of anomalies in the set ofmeasurements. For example, measurement device 40 may have beenincorrectly placed on the wheel when acquisition module 44 obtained themeasurements, one or more sensors in acquisition module 44 may havemalfunctioned, and/or the like. Similarly, the set of previousmeasurements may be inaccurate. Additionally, a different railway wheelmay have been measured.

In any event, in decision M3, mode module 48 determines whetherevaluation module 46 detected an anomaly in the set of measurements. Ifso, mode module 48 can change a measurement mode for measurement device40 to a re-measure mode and attempt to rectify the anomaly. To thisextent, mode module 48 can request that user 16 re-measure theparticular wheel in process M1. Should evaluation module 46 againidentify one or more anomalies, mode module 48 can request that user 16re-measure the wheel in one or more different locations. In this manner,mode module 48 can determine if a local defect may be present in theprevious measurement location. Should evaluation module 46 againidentify one or more anomalies, mode module 48 can request that user 16identify the wheel (e.g., location on the vehicle, type in the serialnumber, and/or the like) to ensure that the correct measurements arebeing compared. If the wheel measurements are for the same wheel, modemodule 48 can store the measurement data, flag the wheel for subsequentfollow up, and return to the normal measurement mode.

Additionally, when preliminary measurement data is available, schedulingmodule 32 can identify one or more wheels that may have a local defect,such as a flat spot, as a suspect wheel, which can be communicated tomeasurement device 40 (e.g., together with wheel data 60). In this case,during the normal measurement mode, in decision M4, mode module 48 candetermine whether the wheel is a suspect wheel. If so, then mode module48 can temporarily switch to a follow up mode. To this extent, inprocess M5, mode module 48 can request that user 16 perform some followup evaluation/measurement of the wheel. For example, if the preliminarymeasurement data indicates that a flat spot may be present, user 16 canbe prompted to obtain measurement data for the center of the flat spot.Subsequently, evaluation module 46 can determine a depth of the flatspot based on, for example, a difference between the flange heightsmeasured in the center of the flat spot and in another location on thewheel. Similarly, evaluation module 46 can calculate a lateral extent ofthe flat spot based on its measured depth. In an embodiment, acquisitionmodule 44 can measure the flange height to an accuracy of less than fivemils. In this case, evaluation module 46 can measure a flat spot lessthan one inch in diameter.

Additionally, evaluation module 46 can evaluate a related set of wheels.For example, in decision M6, evaluation module 46 can determine if bothwheels of an axle have been measured. If so, in process M7, evaluationmodule 46 can evaluate an operability of the axle. For example,evaluation module 46 can determine whether the wheel diameters arewithin safe tolerances (e.g., a difference in the diameters issufficiently small). If not, then evaluation module 46 can flag the axlefor follow up action. In particular, one or both wheels can be replacedwith wheels having sufficiently close diameters. Similarly, evaluationmodule 46 can evaluate an operability of a vehicle. For example,evaluation module 46 can determine if any reprofiling is required torestore an ideal profile for the particular vehicle (e.g., a wheel truckfor a railway car). In this case, after all wheels on the vehicle havebeen measured, evaluation module 46 can compare the measurements for allof the wheels noting that the smallest diameter wheel will provide thelimiting dimensions on the set of wheels. In any event, in decision M8,mode module 48 determines whether any additional wheels requiremeasurement, and if so, the process returns to process M1.

Mode module 48 can implement various other operating modes. For example,mode module 48 can manage a setup mode during which history module 34provides wheel data 60 to measurement device 40, a synchronize modeduring which interface module 42 uploads the measurement data to datamodule 36, and/or the like. Further, mode module 48 can placemeasurement device 40 into a sleep mode when measurement device 40 hasnot obtained measurements for a period of time and/or been used by user16 or another module. In this case, some or all of the variousemitters/sensors of acquisition module 44 and/or the various interfacedevices of interface module 42 (e.g., wireless communications interface)can be powered off or switched to a low power mode to conserve power.Still further, mode module 48 can manage a configuration mode duringwhich dynamic support system 52 updates one or more features ofmeasurement device 40.

D. Interface Features

Interface module 42 can include various I/O devices that enablemeasurement device 40 to interact with user 16, dynamic support system52, and wheel management program 30. In an embodiment, measurementdevice 40 comprises a handheld measurement device and interface module42 communicates with computing device 14 and/or dynamic support system52 using any type of wireless communications link. In this case,measurement device 40 can be carried by user 16 while he/she inspectswheels, such as those of vehicles on a train. Use of a wirelesscommunications link between wheel management program 30 and measurementdevice 40 reduces a number of potential breakage points for measurementdevice 40. Additionally, wireless communications enable the dynamicsharing of data between the two systems. For example, evaluation module46 can send measurement data and the subsequent evaluation results(e.g., maintenance recommendations, such as retruing) for processing bydata module 36 immediately after a wheel/axle/vehicle has been measuredand without interrupting field operations. Similarly, history module 34can provide preliminary measurement data and/or previous measurementdata for use on measurement device 40 while user 16 is inspecting thewheels (e.g., in a just in time fashion). In this manner, measurementdevice 40 does not need to store all the data in advance of inspectingthe wheels.

Additionally, interface module 42 can include an improved interface foruser 16. To this extent, FIG. 13 shows a more detailed view of anillustrative group of interface devices for a measurement device 40according to an embodiment of the invention. Referring to FIGS. 3 and13, interface module 42 can include a graphical user interface 120,which can display a combination of text and graphics for user 16.Graphical user interface 120 enables interface module 42 to display agraphical representation of the inspection process. For example, asshown, graphical user interface 120 can display a representation of oneor more vehicles (e.g., cars, engines, etc.) and their correspondingwheels. Different colors, patterns, and/or the like can be used todisplay status information for a vehicle/axle/wheel. For example, thestatus information can include a required follow up action (e.g.,retruing, replacement, re-measurement) for a vehicle/axle/wheel, avehicle/wheel currently being inspected, an uninspected/inspected statusfor a wheel/vehicle, a suspect wheel, and/or the like. Additionally,graphical user interface 120 can include text that provides some or allof this information. In this manner, user 16 can more efficiently andconfidently perform the inspection.

Graphical user interface 120 also can enable the selection of variousfunctions and/or input of data using a menu or the like. To this extent,interface module 42 can include a set of user interface controls. Theuser interface controls can comprise a relatively simple keypad 122,which includes a reduced set of input keys (e.g., four) that can beoperated with one hand. Keypad 122 can enable user 16 to scroll throughthe menu and make a selection. Further, interface module 42 can includea trigger 124, which user 16 can use to obtain measurements for a wheel.Trigger 124 can be located anywhere on measurement device 40 so that itis readily accessible when measurement device 40 is in a measurementposition for a wheel. Additionally, trigger 124 can be used inconjunction with keypad 122 to make menu selections and the like, e.g.,with keypad 122 being used to scroll to different options and trigger124 to make the selection.

Interface module 42 also can include other interfaces. For example,interface module 42 can include a light emitter 126 (e.g., a lightemitting diode (LED), miniature bulb, or the like), which canshine/flash when attention is required from user 16. Similarly, aspeaker 128 can be included to provide audio feedback (e.g., on theplacement of measurement device 40, failed reading, or the like), audioinstructions, alarm sounds, and/or the like. Still further, interfacemodule 42 can include a vibration unit 130, which can vibrate to obtainthe attention of user 16. Vibration unit 130 can operate using anysolution, such as a low-power off-axis unit, an electromagnetic unit, apiezolectric unit, and/or the like.

In any event, interface module 42 and dynamic support system 52 canenable user 16 to make various customizations to the operation ofinterface module 42. For example, user 16 can alter one or more aspectsof the content of graphical user interface 120, such as a language, apoint size, etc., of text, a color and/or pattern scheme, and/or thelike. Further, user 16 can customize how interface module 42 presentsinformation, e.g., vibration, visual, audio, and/or light. Stillfurther, user 16 can use interface module 42 to make one or morecustomizations to an inspection schedule, such as an order of inspectionfor the wheels of a vehicle, vehicles in the train, or the like.

E. Self-Health Features

Measurement device 40 also can include a self-health module 49, whichmonitors an operability of measurement device 40. For example,measurement device 40 can include a power system that includes a set ofintegrated battery packs that are modular and removable, batteries thatcan be recharged without removal (thereby eliminating a potentialbreakage point) using an inductive charging system, and/or the like.Regardless, self-health module 49 can track power usage and determine anamount of available power from the power system before a recharge willbe required. The amount of available power can be displayed to user 16as a fuel gauge (as shown in FIG. 13), as a number of minutes, as anumber of wheel measurements, and/or the like.

Additionally, self-health module 49 can include a set of internal and/orexternal sensors 132 (FIG. 13) that can measure various operationalenvironment attributes of measurement device 40. For example, the set ofsensors 132 can include one or more sensors for measuring a drop, ashock, a high speed impact, vibration, a temperature extreme, internalmoisture, and/or the like, which can be monitored and evaluated byself-health module 49. Upon the detection of an abnormal event (e.g.,measured value is beyond an acceptable range) or a series of abnormalevents, self-health module 49 can perform one or more actions, such asperform a self-diagnostic test of one or more of the modules (e.g.,measurement sensors), shut down one or more of the modules, notify user16, communicate a status for processing by wheel management program 30,and/or the like. In this manner, self-health module 49 can detect apattern of use and/or abuse, which may lead/have led to a failure of oneor more modules of measurement device 40. Still further, self-healthmodule 49 can periodically provide the monitored data for processing ondynamic support system 52, which can maintain a history of the variousoperational environment attributes to which the particular measurementdevice 40 has been subjected.

Further, self-health module 49 can manage a calibration schedule thatrequires one or more of the sensors to be periodically checked foraccuracy and any required adjustments performed. To this extent,self-health module 49 can monitor one or more return to zero sensors orthe like to ensure that a sensor has fully extended/retracted afterbeing used to obtain a measurement. In the event that the return to zerosensor does not activate, self-health module 49 can notify user 16 priorto another measurement being performed. User 16 can attempt to takecorrective action, stop use of measurement device 40, and/or the like.

IV. Alternatives

While shown and described herein as a method and system for managingrailway wheels and train inspections, it is understood that theinvention further provides various alternative embodiments. For example,in one embodiment, the invention provides a computer program stored on acomputer-readable medium, which when executed, enables a computer systemto manage a set of railway wheels and/or perform a train inspection. Tothis extent, the computer-readable medium includes program code, such aswheel management program 30 (FIG. 3), which implements the processdescribed herein. It is understood that the term “computer-readablemedium” comprises one or more of any type of tangible medium ofexpression (e.g., physical embodiment) of the program code. Inparticular, the computer-readable medium can comprise program codeembodied on one or more portable storage articles of manufacture, on oneor more data storage portions of a computing device, such as memory 22A(FIG. 3) and/or storage system 22B (FIG. 3), as a data signal travelingover a network (e.g., during a wired/wireless electronic distribution ofthe computer program), on paper (e.g., capable of being scanned andconverted to electronic data), and/or the like.

In another embodiment, the invention provides a method of generating asystem for managing railway wheels and train inspections. In this case,a computer system, such as computer system 12 (FIG. 3), can be obtained(e.g., created, maintained, having made available to, etc.) and one ormore programs/systems for performing the process described herein can beobtained (e.g., created, purchased, used, modified, etc.) and deployedto the computer system. To this extent, the deployment can comprise oneor more of: (1) installing program code on a computing device, such ascomputing device 14 (FIG. 3), from a computer-readable medium; (2)adding one or more computing devices to the computer system; and (3)incorporating and/or modifying one or more existing devices of thecomputer system, to enable the computer system to perform the processdescribed herein.

In still another embodiment, the invention provides a business methodthat performs the process described herein on a subscription,advertising, and/or fee basis. That is, a service provider could offerto manage railway wheels and train inspections as described herein. Inthis case, the service provider can manage (e.g., create, maintain,support, etc.) a computer system, such as computer system 12 (FIG. 3),that performs the process described herein for one or more customers. Inreturn, the service provider can receive payment from the customer(s)under a subscription and/or fee agreement, receive payment from the saleof advertising to one or more third parties, and/or the like.

As used herein, it is understood that “program code” means anyexpression, in any language, code or notation, of a set of instructionsthat cause a computing device having an information processingcapability to perform a particular function either directly or after anycombination of the following: (a) conversion to another language, codeor notation; (b) reproduction in a different material form; and/or (c)decompression. To this extent, program code can be embodied as some orall of one or more types of computer programs, such as anapplication/software program, component software/a library of functions,an operating system, a basic I/O system/driver for a particularcomputing, storage and/or I/O device, and the like.

The foregoing description of various aspects of the invention has beenpresented for purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed, and obviously, many modifications and variations arepossible. Such modifications and variations that may be apparent to anindividual in the art are included within the scope of the invention asdefined by the accompanying claims.

1. A handheld measurement device comprising: a system for obtaining aplurality of measurements for a wheel; and a system for evaluating atleast one of the plurality of measurements with at least one anticipatedwheel property to determine a validity of the at least one of theplurality of measurements.
 2. The device of claim 1, further comprisinga system for requesting a re-measurement of the wheel based on theevaluating.
 3. The device of claim 1, wherein the system for evaluatingincludes: a system for obtaining a set of previous measurements for thewheel; and a system for comparing the set of previous measurements withat least one of the plurality of measurements.
 4. The device of claim 1,wherein the system for obtaining includes a system for detecting when aset of sensing devices are correctly aligned with the wheel.
 5. Thedevice of claim 1, wherein the system for obtaining includes at leastone linear sensor.
 6. The device of claim 1, wherein the system forobtaining includes a sensor array.
 7. The device of claim 1, furthercomprising: a graphical user interface; and a set of user interfacecontrols.
 8. The device of claim 7, further comprising a system forgraphically displaying on the graphical user interface a status of atleast one of: a wheel, an axle, a car, or an engine.
 9. The device ofclaim 1, further comprising: a system for managing an inspectionschedule for a train; and a system for managing a plurality ofmeasurement modes.
 10. The device of claim 1, further comprising asystem for monitoring an operability of the device.
 11. The device ofclaim 1, further comprising a wireless communications system forcommunicating with at least one of: a wheel management system or adynamic support system.
 12. A measurement system comprising: a handheldmeasurement device including: a system for managing an inspectionschedule; a system for obtaining a plurality of measurements for awheel; and a system for managing a plurality of measurement modes. 13.The measurement system of claim 12, further comprising a system formanaging wheel measurement for a plurality of trains in communicationwith the handheld measurement device.
 14. The measurement system ofclaim 12, further comprising a system for obtaining a set of preliminarymeasurements for the wheel.
 15. The measurement system of claim 12,further comprising a dynamic support system for the handheld measurementdevice.
 16. The measurement system of claim 12, wherein the handheldmeasurement device further includes a system for evaluating at least oneof the plurality of measurements with at least one anticipated wheelproperty.
 17. The measurement system of claim 12, wherein the handheldmeasurement device further includes a system for monitoring anoperability of the device.
 18. A handheld measurement device comprising:a system for obtaining a plurality of measurements for an object; and asystem for monitoring an operability of the device based on a set ofoperational environment attributes of the measurement device.
 19. Thehandheld measurement device of claim 18, further comprising a system forevaluating at least one of the plurality of measurements with at leastone anticipated object property.
 20. The handheld measurement device ofclaim 18, further comprising a wireless communications system forcommunicating with an object management system.
 21. The handheldmeasurement device of claim 18, further comprising a system for managingan inspection schedule for a plurality of related objects.
 22. Thehandheld measurement device of claim 18, further comprising a system formanaging a plurality of measurement modes.
 23. The handheld measurementdevice of claim 18, further comprising a system for graphicallydisplaying an inspection status of at least one of: the object or aplurality of related objects.